Assignment 2 Part 1: Creating the Templates

Step 1: Create the files on Fusion 360

The first stage before going in and producing was to prepare the files on Fusion 360 using the Slicer software. The STL file for the Ferrario GTO 250 was imported into the program then manipulated to create the waffles that will make up the overall shape and form of the car.

Step 2: Laser cutting

After all the waffles and amount of slicing were sorted on Fusion 360 the next step was to begin laser cutting all the layers to be assembled using 3mm pieces of plywood.

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Assignment 2 Part 2: Creating the Initial Assembly of the Car

Step 1: Assembling the Laser Cut Pieces There were many pieces that we laser cut, so it was important to organise the pieces accordingly whilst assembling them. Most pieces fitted in quite well, however there were pieces that required extra force to be properly placed in. Step 2: Adding Masking Tape Layer We decided to add a layer of masking tape over the entire model to give ourselves a better idea on the specific contours and curves of the car. It also helped with dividing the panels of the frame to be delegated to various members of our group.

Task 1: Bowl

The first task we were given to do was to implement various workshop processes to create a bowl-shaped form out of a 2 mm sheet of metal. Step 1: Cutting out the material The initial stages proved to be quite tedious as it involved measuring out dimensions and cutting out the appropriate shape to begin working with. This involved whipping out a protractor to etch the template for the overall base of the bowl. Then with the use of a pruner, we were able to cut out the shape, which actually proved to be quite harder than it looked. To finish off, some sanding was done on the edges to get a more precise cut finish. Step 2: Initial metal beating Now it was time to get into the interesting part, beating the crap out of the material until it provided a form that would somewhat resemble the shape of a bowl. Before any of that happened, it is important that inner circles were drawn out to give visual representation on what areas to hammer down. Next was to grab a wooden templat...

Assignment 2 Part 3: Creating the Individual Panels

Step 1: Creating Paper Templates Before going right into cutting and beating out our aluminium sheet parts, we decided it be best to create templates out of tracing paper to get the most accurate end result as possible. Each segment of the car was divided into specific sections we thought would be best suited for the metal work process. Step 2: Cutting out the Aluminium Sheets The next step was to use the templates we made to create the general shape of the metal sheets that we will use to start forming. This process involved using scribes to create the shape that will be cut out using the cutting shears. Step 3: Initial Forming and Shaping Now that all the sheets have been readily prepared for metal work, it was time to begin shaping our parts and getting an idea of how it will fit all together. Step 4: Further Metal Working I was delegated to work on the back/spoiler of the car and also the front/bumper. After I formed the rough...

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